Engine removal

[inchoate]

I'm pulling the engine out of my Caterham later this week to do some work on it and the engine bay.  Not my first time pulling an engine but it is my first time with a Caterham.  Any general advice?  I don't seem to have a lot of clearance in the front so I was going to pull the engine and transmission together unless I hear otherwise. The car is on stands so I have some space below for tilting etc.

[Vovchandr]

From my very limited experience. Pull out together, use an adjustable leveler to help angle on the way up.  

[SENC]

This is the engine going back into my 65, I'd guess the necessary angle would be similar for yours.

 

 

On thes older ones, the front brake lines run along the top chassis crossmember, and need protecting as the engine makes a close pass and can easily swing and damage.  I use a piece of rubber hose spilt longways, or pipe insulation, to wrap around it.

[IamScotticus]

Raise the car as far off the ground as possible, like 2 feet at least.  Most floor jacks can't go that high but you can do it with blocks.

 

remove the radiator so it doesn't  get damaged.  it's a good time to change hoses to a Samco kit anyway. 

 

if you will be removing the intake manifold, do it before removal and if you're removing the head, remove that too.  These things detached free up space.

 

Get an engine lift leveler.  look that up. 

 

if possible,  get a ganrty crane for engine hoist and move the car for minor latteral adjustments.

 

If you can remove the driveshaft with the transmission, it will prevent oil loss.

 

protect or remove the headlights.

 

Lotz of cardboard to protect surfaces (from you, especially)

[IamScotticus]

https://m.northerntool.com/shop/tools/product_200696886_200696886

[CarlB]

My car has a Zetec so the engine is a little longer. I use a Load leveler so you can change the angle of the engine as it goes in and out of the car.

 

https://www.harborfreight.com/automotive/lifts-cranes-stands/2-ton-capacity-load-leveler-60659.html

[wemtd]

As noted above:

Elevate the vehicle (not trusting jack stands I use concrete blocks & Timbers - or a lift if you've got one).

Remove all ancillaries from the engine & prop shaft so it will clear the frame. Using straps around the engine at it's neutral balance point (cylinder 4 in my case) and an overhead hoist: unbolt the engine/gearbox and lower onto a dolly & slide out.  Perform your selected maintenance project or annual dusting & polishing tasks. Note: This method keeps the gearbox level which avoids the gear oil pouring out the T9's tailshaft all over the floor (no matter what I've tried it still leaks out if inclined).  It's also easier to re-fill/change gearbox oil outside the car. 

I've done this more times than I care to admit (possibly rivaling Folis Jone's record). installation is the reverse. Budget twice the time for re-assembly than removal. A little bonding with your car & exchange of blood for oil is part of ownership.

 

cheers

p.

 

Edited June 14, 2022 by wemtd

[inchoate]

I've got a load leveler for my hoist and the car is on blocks about 18" off the ground.  It never occurred to me to drop the engine out the bottom but that's a really good idea.  I don't have a lift though, so maybe next time.

 

I wasn't aware of the issues with the gearbox loosing it's oil through the tailshaft, so I'll prep for that. 

[fastg]

I have found one way to control oil loss from the gearbox tail shaft is to zip tie a rubber glove over the end. Looks strange but works well. 

 

Graham 

[IamScotticus]

Replace the output seal and speedo seal while its out

[TexasDreamer]

 For the type 9 transmission with mechanical speedometer cable, watch out for the right-angle speedo connection to the transmission. It is fragile and expensive. the two parts in the picture were one part before I broke it.

 

[bball7754]

I experienced the trans oil leaking several times, and then started to separate the engine before removal.  
 

But last year I purchased these:

 

https://www.amazon.com/gp/product/B000P0U04G/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

 

I used them when I I removed the engine in the Mallock last month, and not a drop of trans fluid leaked out.  I was amazed, and pleasantly surprised.

 

Steve

[IamScotticus]

10 hours ago, TexasDreamer said:

 For the type 9 transmission with mechanical speedometer cable, watch out for the right-angle speedo connection to the transmission. It is fragile and expensive. the two parts in the picture were one part before I broke it.

 

Been debating on going with a GPS/sensor speedo for T-9.

[IamScotticus]

10 hours ago, bball7754 said:

I experienced the trans oil leaking several times, and then started to separate the engine before removal.  
 

But last year I purchased these:

 

https://www.amazon.com/gp/product/B000P0U04G/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

 

I used them when I I removed the engine in the Mallock last month, and not a drop of trans fluid leaked out.  I was amazed, and pleasantly surprised.

 

Steve

Bought it $12.

Thanks!😁

Then bought ten more things I didn't know I needed. 

Darn you!😡

[inchoate]

I started preliminary removal and I have a stupid question.  Should the output shaft of the transmission stay with the transmission or the u joint?  mine looks like it's pulling out of the back of the transmission.  My T9 service manual isn't much help as it covers service, not removal.

[JohnCh]

It stays with the U-joint and acts like the plug for the transmission.  When this comes out, so does the oil.

 

-John

[IamScotticus]

the drive shaft just slips into the rear of the T9.  they slide for movement and flexing, etc.

when it comes out,  and the T9 is tilted,  oil will pour out.

This isn't an issue as long as you are capturing it.  but can get messy.   other option is to unbolt shaft from diff.  must replace shaft the same position it was.

caution, the shaft can still slip off.

[inchoate]

That makes sense.  I think the exploded diagram I have for the T9 is incomplete and so it wasn't entirely clear what was supposed to be going on.  I'm tiptoeing on this one because I'd really rather not break anything. 

[IamScotticus]

.

Edited June 15, 2022 by IamScotticus

[inchoate]

That wasn't so bad.  Pretty sure I managed to not damage anything.